Support mechanical design and structural analysis efforts for key UAV subsystems across the entire product lifecycle: concept, prototyping, testing, production, and field support. Develop innovative, manufacturable mechanical designs optimized for UAV flight performance under varying operational conditions, ensuring structural, thermal, and functional requirements are met through rigorous analysis and validation. Analyze initial aerostructures designs against preliminary mass properties targets and strength and stiffness requirements.
Create and maintain high-quality 3D CAD models, detailed engineering drawings, and manufacturing documentation using SolidWorks, emphasizing GD&T principles to ensure precision and manufacturability. Validate and optimize designs using a combination of hand calculations, finite element analysis (FEA), and physical testing. Drive high-cadence iterative design and analysis cycles, supporting rapid prototyping and cross-functional design reviews to incorporate test feedback promptly and continuously improve hardware through agile development processes.
Collaborate cross-functionally with electrical engineers, flight-test engineers, and manufacturing teams to integrate complex mechanical and electromechanical systems, including servos, pumps, sensors, cameras, PCBAs, wiring harnesses, and connectors. Support technical reviews and contribute to design and analysis decisions, ensuring robust engineering practices and adherence to program requirements. Support rapid prototyping efforts with hands-on experience building functional prototypes in a shop environment, iterating designs based on real-world results and test data.
Troubleshoot mechanical and electromechanical issues through root cause analysis and implement effective corrective actions. Contribute to configuration management and documentation control, maintaining clear versioning of CAD files, assemblies, and design revisions. Build and maintain engineering rigor by contributing to the development of company-wide best practices, including CAD standards, documentation protocols, and hardware management processes.
Write detailed build documentation and collaborate hands-on with technicians during hardware integration and assembly. Support Design for Manufacturability (DFM) efforts, working closely with internal and external manufacturing teams to refine parts and processes—including additive manufacturing, CNC machining, sheet metal, injection molding, and composite tooling and fixturing. Leverage additive manufacturing and traditional fabrication methods to produce high-performance UAV components.
Perform other duties as directed
Required Qualifications
Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline. 'U.S. Person' as defined by 22 CFR § 120.62 required due to ITAR regulations , which includes U.S. citizens, lawful permanent residents (Green Card holders), or protected individuals under asylee or refugee status 5+ years of mechanical design experience, working directly with aircraft design. Minimum 1 year of hands-on experience in structural analysis.
Strong foundation in mechanical engineering fundamentals; structures, fluid systems, thermal management, and mechanisms. Hands-on design engineering experience, with proven application of design-for-manufacturability (DFM) principles. Experience analyzing primary and secondary aircraft structures using industry-standard tools and methods. Demonstrated ability to perform structural modeling and analysis of mechanical components and assemblies.
Proficiency in first-order structural analysis and hand calculations, including free body diagrams, statics, and mechanics of materials. Experience in SolidWorks, including surfacing, top-down design, and advanced modeling techniques, plus strong knowledge of GD&T principles. Experience integrating mechanical designs with electrical systems, including PCBAs, wiring harnesses, and electromechanical components such as servos and sensors. Direct application of DFM and designing for additive, traditional, and composite manufacturing methods, including tooling and fixturing for composite assemblies.